Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit kind a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for contemporary convenience products because of its high quality and experience. Since early 2019, the vacuum provide to its tray sealer packaging machines has been exceptionally energy-efficient following the set up of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its convenience foods in a contemporary facility in Jagsthausen, a town within the German state of Baden-Württemberg. To allow it to provide contemporary raw produce all yr round, the corporate has its personal growers in Germany and Portugal. Cultivation in two different local weather zones ensures that the whole product range may be supplied year-round, offered to finish customers across Germany by way of supermarket chains and low cost stores. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, as nicely as for third celebration brands. Gartenfrisch Jung’s historical past dates back to 1795. What started out as a small piece of farmland has now reworked into built-in, controlled growers of salads and greens and another arm for processing these merchandise. As a household business, Gartenfrisch Jung has been passed from one technology to the following ever since it started. The expertise gained consequently has therefore grown steadily, resulting in the company’s profitable improvement and a excessive quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw food every day. This is equivalent to handling 2,000 pallets, that are then delivered to clients by eighty refrigerated automobiles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging traces with tray sealer packaging machines. In the previous, these packaging machines were geared up with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These 13 vacuum pumps were used to evacuate the trays to the required vacuum degree previous to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran constantly all through these shifts, apart from during breaks. During a third shift, the manufacturing facilities are cleaned whereas all equipment is stationary.
Jochen Neff, who is in management of know-how at Gartenfrisch Jung, was in search of an alternate vacuum supply, as a outcome of the heat radiated by the thirteen vacuum pumps was placing a strain on the air-con system in the production amenities, that are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an put in motor output of over 50 kilowatts. The vacuum specialists from Busch Vacuum Solutions analyzed the situation and really helpful a centralized vacuum supply, which might be arrange in a non-air-conditioned room exterior the production amenities.
Because Jung’s convenience merchandise have the ideal vacuum for packaging at a vacuum level of 400 millibars, Busch really helpful utilizing MINK claw vacuum pumps. This kind of vacuum pump has the best efficiency issue out of all mechanical vacuum pumps. This is a results of their contact-free operating principle, which signifies that the shifting elements inside the vacuum pump don’t are available in contact with each other. In flip, no oil-based lubrication is required and all upkeep work related to the use of oil as an operating fluid is eliminated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), each of which was geared up with a motor with a nominal motor score of eight kilowatts. However, one of many three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to make certain that all three vacuum pumps have the same number of working hours.
Centralizing the vacuum provide enabled the whole put in motor rating to be reduced from 50.2 to sixteen kilowatts (Fig. 3) if we assume that two of the vacuum pumps run at 60 Hertz, i.e. most power. This would correspond to a sixty eight percent reduction in power consumption. However, in apply Jochen Neff has found that only one of many two MINK claw vacuum pumps is normally in use and that this tends to run at a reduced rotational velocity. After เพรสเชอร์เกจไฮดรอลิค of months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the complete vacuum provide. This is principally linked to the reality that the twelve packaging lines do not all all the time run at maximum velocity and not the entire machines are in use on a daily basis. The demand-based control system then decreases the rotational velocity to cut back the output, meaning that the system only provides the efficiency that is truly required. In follow, this equates to vitality financial savings of over ninety percent for vacuum generation.
The new centralized vacuum system was put in in April 2019 and has been in use each since. It is linked to the packaging machines through a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each ensure that the required vacuum stage is on the market in the packaging chambers as quickly as it’s wanted in the packaging cycle. Removing the 13 authentic vacuum pumps from the manufacturing areas relieved pressure from the air con system. This meant that the air conditioning system might be turned down to maintain the room temperature between 5 and 6 levels Celsius. The financial savings in energy costs on account of decreasing the air conditioning output have not been measured. However, it might possibly usually be assumed that the change resulted in a significant discount within the power consumed by the air con system.
Thanks to the vacuum system’s redundant design, maintenance may be carried out on the person MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is proscribed primarily to the annual preventive change in gear oil. This is carried out by a Busch service technician. With the centralized vacuum system, Jochen Neff has created a extremely energy-efficient, dependable and economical vacuum provide for packaging his comfort merchandise.
Fig: 1: One of twelve strains used to package deal comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the 2 vacuum vessels within the background
Fig. 3: Comparison of vitality consumption for a decentralized and centralized vacuum supply
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020
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